Search Results (20)

The most appropriate operating conditions are necessary in industrial manufacturing to maintain product quality and consistency. In this respect, Clean-In-Place (CIP) is a widely adopted method in the food, beverage, pharmaceutical, and chemical industries, which ensures equipment cleanliness without dismantling. A detailed analysis and simulation for the assessment of accuracy, computational efficiency, and adaptability in fault detection, such as valve malfunction, pump failure, and sensor error, are necessary for the CIP system. Advanced fault detection methods within a five-tank CIP model are investigated in this paper, comparing the extended Kalman filter (EKF) with the unscented Kalman filter (UKF). Both techniques have their merits for fault detection in complex systems. The results indicate that the UKF mostly performs better than the EKF in treating the nonlinearities of the given CIP system with the chosen system characteristics and fault type. This approach helps improve the reliability and efficiency of the CIP process, thus providing insights into enhancing fault detection strategies in industrial applications. Full article

The recovery concept of cleaning solutions, based on single-phase detergents from cleaning-in-place (CIP) effluents from the dairy industry, is presented. The first step consists of ultrafiltration (UF) (with a cut-off of 5 or 10 kDa) to reduce the high load of milk proteins, followed by nanofiltration (NF) (with a cut-off of 200 Da) to separate low molecular weight lactose. Membrane steps were performed in the concentration mode, achieving a recovery of 75% of the solutions. UF modules reduced 70–85% of chemical oxygen demand (COD), 99% of milk proteins, and 45–70% of lactose, limiting the susceptibility of NF modules to fouling. Combined with nanofiltration, the efficiency of the purification system is 100% for proteins and more than 99% for lactose. The solutions recovered in the proposed purification variants are recognized as sodium hydroxide solutions with a surfactant admixture, and they can be successfully re-used for cleaning processes in the production plant. Full article

The winning of critical raw materials from secondary resources, e.g., from abandoned mines, mining residues, electronic waste or low-grade ores, is a potential source with promising outcomes due to innovative and more efficient extraction methods. The research and education mine “Reiche Zeche” at the TU Bergakademie Freiberg, Germany offers a scientific lab in a real application environment for an in-situ bioleaching section from a low-grade sulfide ore vein with on-site associated membrane downstream processing. The evaluation and resumption of previous research activities showed both the feasibility and the potential for further up-scaling. But there was also potential evaluated for improving the effectiveness, especially in terms of individual process elements within the leaching and membrane cycle as well as regarding microbiology. Based on this, further optimization was carried out and effectiveness was evaluated and compared to the prior state. The results regarding the leaching outcome proved that process optimization leads to stable and continuous leaching process operations as well as to improved and more favorable conditions for the microorganisms due to the implementation of a bioreactor and changing the whole leaching operation from a direct into an indirect process. Furthermore, cleaning in place (CIP) resulted in the maintenance of selectivity despite discontinuous membrane process operation. Full article

Reverse osmosis (RO) spiral wound membrane generation reached 93.5% in 2020, resulting in 14,000 tons of used RO membranes being discarded annually into landfills, which is unprecedented. The current study aims to chemically convert the end-of-life RO membrane, followed by its performance evaluation and microbial removal efficiency on three different sources of water, i.e., tap water (TW), integrated constructed wetland permeate (ICW-P), and membrane bio-rector permeate (MBR-P), respectively. This was accomplished by selecting 6 years of spent Filmtech (LC-LE-4040) thin film composite type brackish water reverse osmosis (BWRO) membrane, followed by alkaline and acidic cleaning for 2 h. Finally, the conversion was carried out by 6% sodium hypochlorite (NaOCl) with 300,000 ppm/h exposure by active system (AS) using the clean in place CIP pump at 2 bars for 10 h duration. The membrane demonstrated 67% water recovery and 1% saltwater rejection, which means RO membrane now converted into recycled RO (R-RO) or (UF) by removal of the polyamide (PA) layer. Water recovery was 67% for TW, 68% for ICW-P, and 74% for MBR-P, respectively, with the consistent saltwater rejection rate of 1% being observed, while R-RO exhibited an effective COD removal of 65.79%, 62.96%, and 67.72% in TW, ICW-P, and MBR-P, respectively. The highest turbidity removal of 96% in the ICW-P was also recorded for R-RO. For morphological properties, SEM analysis of the R-RO membrane revealed a likewise appearance as a UF membrane, while pore size is also comparable with the UF membrane. The most probable number (MPN) also showed complete removal of total coliforms after passing through the R-RO membrane. These features made the R-RO membrane an excellent choice for drinking water treatment and wastewater treatment polishing steps. This solution can help developing nations to be efficient in resource recovery and contribute to the circular economy. Full article

Membrane filtration is a key technology in dairy processing for the separation of dairy liquids to clarify, concentrate, and fractionate a variety of dairy products. Ultrafiltration (UF) is widely applied for whey separation, protein concentration and standardization, and lactose-free milk production, though its performance can be hindered by membrane fouling. As an automated cleaning process commonly used in the food and beverage industries, cleaning in place (CIP) uses large amounts of water, chemicals, and energy, resulting in significant environmental impacts. This study introduced micron-scale air-filled bubbles (microbubbles; MBs) with mean diameters smaller than 5 μm into cleaning liquids to clean a pilot-scale UF system. During the UF of model milk for concentration, cake formation was identified as the dominant membrane fouling mechanism. The MB-assisted CIP process was conducted at two bubble number densities (2021 and 10,569 bubbles per mL of cleaning liquid) and two flow rates (130 and 190 L/min). For all the cleaning conditions tested, MB addition largely increased the membrane flux recovery by 31–72%; however, the effects of bubble density and flow rate were insignificant. Alkaline wash was found to be the main step in removing proteinaceous foulant from the UF membrane, though MBs did not show a significant effect on the removal due to the operational uncertainty of the pilot-scale system. The environmental benefits of MB incorporation were quantified by a comparative life cycle assessment and the results indicated that MB-assisted CIP had up to 37% lower environmental impact than control CIP. This is the first study incorporating MBs into a full CIP cycle at the pilot scale and proving their effectiveness in enhancing membrane cleaning. This novel CIP process can help reduce water and energy use in dairy processing and improve the environmental sustainability of the dairy industry. Full article

The main goal of this study is to evaluate possible reuse routes of effluents from adairy plant. First, the water flow in the plant was evaluated. All water consumed and effluents generated by the industrial process were quantified and characterized. In addition, the water quality parameters required for different industrial activities were assessed. Secondly, a treatment system using a membrane bioreactor and a nanofiltration reactor, from a study previously conducted by the authors, was considered. Then, a water pinch analysis was carried out through the application of the collected data using the Water Pinch software. Both direct reuse/recycle and regeneration schemes were investigated. In this context, although the direct reuse/recycle of effluents were shown to be able to reduce the freshwater use for the clean-in-place process (CIP) by 33.4%; the schemes with the regeneration of the effluents showed up to 66.7% and 95.4% of freshwater reduction for the CIP and general processes, respectively. Finally, four water reuse routes were proposed. The proposed route combining the most advanced treatment technologies studied showed the best performance in terms of reduction of the total freshwater consumption (69.5%) in the dairy plant. Full article

Increasing contamination of wastewater with antibiotics used in agriculture, animal husbandry, and medicine is a serious problem for all living things. To address this important issue, we have developed an efficient platform based on a high specific surface area hexagonal boron nitride (BN) coating formed by numerous nanopetals and nanoneedles. The maximum sorption capacity of 1 × 1 cm² BN coatings is 502.78 µg/g (tetracycline, TET), 315.75 µg/g (ciprofloxacin, CIP), 400.17 µg/g (amoxicillin, AMOX), and 269.7 µg/g (amphotericin B, AMP), which exceeds the sorption capacity of many known materials. Unlike nanoparticles, BN-coated Si wafers are easy to place in and remove from antibiotic-contaminated aqueous solutions, and are easy to clean. When reusing the adsorbents, 100% efficiency was observed at the same time intervals as in the first cleaning cycle: 7 days (TET) and 14 days (CIP, AMOX, AMP) at 10 µg/mL, 14 days (TET, CIP, and AMOX) and 28 days (AMP) at 50 µg/mL, and 14 days (TET) and 28 days (CIP, AMOX and AMP) at 100 µg/mL. The results obtained showed that TET and CIP are best adsorbed on the surface of BN, so TET was chosen as an example for further theoretical modeling of the sorption process. It was found that adsorption is the main mechanism, and this process is spontaneous and endothermic. This highlights the importance of a high specific surface area for the efficient removal of antibiotics from aqueous solutions. Full article

Food allergies are an important global health concern, with many countries following the World Health Organisation’s guidelines with regards to due labelling of foods and, as such, providing forewarning about the presence of potential allergens to potential consumers. While for some produce, the link to specific allergens might be very clear to most consumers, this is not the case for all produce. People with specific food-related allergies usually know what to look out for, but occasionally, unexpected allergens are present in trusted produce. Beer is known to most to contain barley, which will contain gluten-like proteins that can cause allergic reactions in some people. Similarly, beer might contain sulphites and other potential allergens traditionally associated with beers. This review aims to examine a wide range of allergens that have entered the beer production process in recent years. As a result, examples of beers that contain one or more of the 14 EU-UK listed allergens are described, different allergen regulations in different countries are emphasised and their impact explained, and a number of case studies involving allergic reactions following exposure to and the ingestion of beer are highlighted. Full article

The paper presents the results concerning the influence of concentration and storage time on the equilibrium surface tension of chemical solutions used in a clean-in place (CIP) system. Standard cleaning solutions (prepared under laboratory conditions) and industrial solutions (used in a CIP system in a brewery) were subjected to tests. Solutions from the brewery were collected after being regenerated and changes in equilibrium surface tension were studied during a three-month storage. In the statistical analysis of the solutions, standard deviations were determined in relation to the averages, and a Tukey’s multiple comparison test was performed to determine the effect of dependent variables on the surface tension of solutions. From the results, a nonlinear regression model was developed that provided a mathematical description of the kinetics of changes in the wetting properties of the solutions during their storage. A linear–logarithmic function was adopted to describe the regeneration. Numerical calculations were performed based on the nonlinear least squares method using the Gauss–Newton algorithm. The adequacy of the regression models with respect to the empirical data was verified by the coefficient of determination R and the standard error of estimation Se. The results showed that as the concentration of the substance in the cleaning solution increased, its wetting properties decreased. The same effect was observed with increased storage time as the greatest changes occurred during the first eight weeks. The study also showed that the use of substances to stabilize the cleaning solutions prevented deterioration of their wetting properties, regardless of the concentration of the active substance or storage time. Full article

For providing advanced desalination the combination of the improvement of water recovery ratio in the reverse osmosis (RO) process and the No-Chlorine/No-Sodium Bisulfite (SBS) Dosing process was studied. In order to prevent membrane fouling even in high recovery water operations, an advanced two-stage design was implemented to (1) control the permeate flux through the RO membrane module, (2) optimize the system to reduce contaminant build-up and (3) eliminate the use of chlorine and SBS, which can accelerate membrane fouling. The system was evaluated by monitoring the biofouling and the microorganisms proliferation on the membrane surface based on membrane biofilm formation rate (mBFR). The pilot plant was operated in the condition of a water recovery rate of 55%. As a result, the system was operated for longer than four months without membrane cleaning (clean in place; CIP) and the possibility of operation for seven months without CIP was confirmed by the extrapolation of the pressure values. In addition, the mBFR is a reliable tool for water quality assessment, based on a comparison between the fouling tendency estimated from the mBFR and the actual membrane surface condition from autopsy study and the effectiveness No-Chlorine/No-SBS Dosing process was verified from mBFR of pretreated seawater. Full article

Measuring the bacterial growth potential of seawater reverse osmosis (SWRO) feed water is an issue that is receiving growing attention. This study developed and demonstrated the applicability of the flow-cytometry (FCM)-based bacterial growth potential (BGP) method to assess the biofouling potential in SWRO systems using natural microbial consortium. This method is relatively fast (2–3 days) compared to conventional bioassays. The effect of the potential introduction of nutrients during measurement has been studied thoroughly to achieve the lowest measure value of about 45,000 cells/mL, which is equivalent to about (10 µg-C glucose/L). The BGP method was applied in two full-scale SWRO plants that included (i) dissolved air flotation (DAF) and ultra-filtration (UF); (ii) dual-media filtration (DMF) and cartridge filter (CF), which were compared with the cleaning frequency of the plants. A significant reduction (54%) in BGP was observed through DAF–UF as pre-treatment (with 0.5 mg Fe³⁺/L), while there was a 40% reduction by DMF–CF (with 0.8 mg Fe³⁺/L). In terms of the absolute number, the SWRO feed water after DAF–UF supports 1.5 × 10⁶ cells/mL, which is 1.25 times higher than after DMF–CF. This corresponds to the higher cleaning-in-place (CIP) frequency of SWRO with DAF–UF compared to DMF–CF as pre-treatment, indicating that the BGP method has an added value in monitoring the biofouling potential in SWRO systems. Full article

To find an environmentally friendly and energy efficient alternative to acidic detergent for a milking system clean-in-place (CIP) process, this study investigated the feasibility of applying slightly acidic electrolyzed water (SAEW) alone to wash the system by cleaning soiled stainless steel (304) pipes, rubber gaskets, and PVC milk hoses, which were used in the milking system. The results showed that SAEW with appropriate parameters could achieve the same or even better hygienic effects compared with commercial detergent. Using response surface models, the SAEW parameters required to clean stainless steel were optimized at 9.9 min for the treatment time, 37.8 °C for the water temperature, and 60 mg/L for the available chlorine concentration; and were 14.4 min, 29.6 °C, and 60 mg/L for rubber gasket and PVC samples, respectively. After washing with the optimized parameter combination, bacteria and adenosine triphosphate on the three materials were almost non-detectable, indicating that SAEW has the potential to replace acidic detergents in CIP milking systems. Full article

Food manufacturers are aiming to manage the levels of cross-contamination of allergens within food processing plants and ultimately move away from precautionary labelling. Hence, the need for rapid methods to detect allergens cross-contamination. A sensitive and selective label-free nanoMIPs based sensor was developed and tested for the detection of β-lactoglobulin (BLG). NanoMIPs were synthesized using solid-phase synthesis and appeared as spherical nanoparticles with sizes ranging from 264–294 nm, using dynamic light scattering (DLS). The nanoMIPs were functionalized with amine groups and attached to the surface of the SPR gold chip via amine-coupling protocol. The SPR nanoMIPs-based sensor demonstrated a detection limit of 3 ng mL⁻¹ (211 pM) over a linear range of 1–5000 ng mL⁻¹, with binding affinity of 7.0 × 10⁻⁸ M and specificity towards BLG. With further testing and final optimization, the developed nanosensor can be integrated on-line or at-line cleaning-in-place (CIP) wash systems, allowing to effectively monitor milk protein allergens as a rapid, point-of-source methodology. Full article

One of the main strategies for maintaining the optimal hygiene level in dairy processing facilities is regular cleaning and disinfection, which is incorporated in the cleaning-in-place (CIP) regimes. However, a frail point of the CIP procedures is their variable efficiency in eliminating biofilm bacteria. In the present study, we evaluated the susceptibility of strong biofilm-forming dairy Bacillus isolates to industrial cleaning procedures using two differently designed model systems. According to our results, the dairy-associated Bacillus isolates demonstrate a higher resistance to CIP procedures, compared to the non-dairy strain of B. subtilis. Notably, the tested dairy isolates are highly persistent to different parameters of the CIP operations, including the turbulent flow of liquid (up to 1 log), as well as the cleaning and disinfecting effects of commercial detergents (up to 2.3 log). Moreover, our observations indicate an enhanced resistance of poly-γ-glutamic acid (PGA)-overproducing B. subtilis, which produces high amounts of proteinaceous extracellular matrix, to the CIP procedures (about 0.7 log, compared to the wild-type non-dairy strain of B. subtilis). We therefore suggest that the enhanced resistance to the CIP procedures by the dairy Bacillus isolates can be attributed to robust biofilm formation. In addition, this study underlines the importance of evaluating the efficiency of commercial cleaning agents in relation to strong biofilm-forming bacteria, which are relevant to industrial conditions. Consequently, we believe that the findings of this study can facilitate the assessment and refining of the industrial CIP procedures. Full article

Performance of anion exchange membranes (AEMs), including polyvinyl chloride (PVC) as backing and binder, decreases during a repetitive cleaning-in-place (CIP) treatment using alkali. In this study, we have systematically performed two optical analyses, relative total visible (VIS) reflectance and handheld X-ray fluorescence (XRF), for alkali-attacked commercially available AEM (Neosepta^® AMX, Tokyo, Japan) with different NaOH immersion conditions (0–1.0 M NaOH at 40–80 °C for 0–168 h). The VIS reflectance and XRF data were then compared with the electrical and mechanical performances (i.e., membrane resistance, proton rejection, amount of fixed-charge sites, and Young’s modulus) of the alkali-attacked AMXs. The result indicated that there are clear linear relationships between their performances and both VIS reflectance and XRF data especially at 40 °C, indicating both optical analyses have a good possibility as a quick diagnosis-in-place (DIP) to predict the resulting performance of the alkali-attacked AMXs. In addition, we also found a clear linear relationship between VIS reflectance and XRF data, so that polyene formations through dehydrochlorination of PVC during alkali attack is one of dominant mechanisms for the performance reduction of the alkali-attacked AMX at 40 °C. These results are promising to be useful for the analysis of ion exchange membranes (IEMs) used in real commercial processes on-site in future. Full article